May 10, 2008 - Baffle Gussets
Now for a little work on the side baffles.  The task was to bend the bottom edge 90 degrees so that it would support the floor baffle.  I need to trim away some of the bottom edge, first, though.  This is the right side baffle marked for trimming.
 
And the left.
 
I did the trimming with the Shears and a little filing.  Now we're ready for bending. 
 
The instructions tell you how to bend using the rivet gun.  Worked pretty well.  30 psi worked pretty well for me.
 
Right side done.
 
Working on the left side.
 
And the left side is done.
 
Next task was to make gussets that attack the side baffles to the floor baffles, while curving to match the cowl inlet curve.
 
First I made a stiff paper template for each side.  I sacrified a manila folder for the job.
 
Taped the oversize gusset template into position.  I marked 1 1/2 inch and 2 inch marks on the side and bottom baffles, then marked the gusset template.
 
Same with the right side, which is quite a bit different size than the left.
 
I cut the gusset templates down to size, then traced them on the .032 sheet aluminum -- supplied with the kit, as always.
 
Now for the hard part:  bending the gusset.  I used the same rivet gun technique as with the side baffles.
 
It worked reasonably well.  I don't know how else I could have done it, actually.  .032 thick aluminum is fairly thick when it comes to bending.
 
The left gusset fits pretty well.
 
The right will need a little more trimming.
 
I started fitting the front baffles.  I started with the right, since it clecos to the right floor baffle flange.  It also clecoed nicely to the bracket on the top center of the engine. 
 
A close up of where the front right baffle clecos to to the right floor baffle flange.
 
Then using the predrilled center hole, I clecoed the left front baffle to to the right. 
 
 
The right front baffle fit perfectly around the engine.  But the left did not, although it is hard to tell in this image.
 
The left front baffle will need some trimming to get it fit closer to the engine.
 
 
Previous
Home
Next